THE CONCRETE BRIDGE MAGAZINE

SPRING 2017

ASPIRE is a quarterly magazine published by PCI in cooperation with the associations of the National Concrete Bridge Council. The editorial content focuses on the latest technology and key issues in the Concrete Bridge Industry.

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Page 17 of 55

PROJECT
THE ESTRELLA UNDERPASS AT GRAND AVENUE
by John Lange, Stanley Consultants
State Route (SR) 303L is a 40-milelong new freeway in the western and northwestern portions of the greater Phoenix, Ariz., metropolitan area. Originally known as the Estrella Freeway, it opened in 1992 as a two-lane freeway. Growth and future traffic projections have driven the need to expand SR 303L to an ultimate configuration of six lanes in each direction. This growth in the Phoenix metro area has had a significant impact on bridge design and construction methodology. Bridge widening on existing freeways and over busy urban arterials often requires bridge engineers to explore innovative designs to maintain traffic during major bridge construction activities.
The Estrella Underpass at Grand Avenue bridge carries SR 303L over U.S. 60 (Grand Avenue) and the Burlington Northern Santa Fe (BNSF) Railway. The challenge of maintaining traffic on U.S. 60 during construction was complicated by the limited detour options. High traffic volumes of 24,000 and 12,700 vehicles per day on U.S. 60 and SR 303L, respectively, precluded extended closures with off-site detours. Consequently, the final design of this bridge was driven primarily by the need to maintain both vehicular and railway traffic through this interchange.
Innovating from the Start
The original project design concept report proposed widening on both sides of the existing bridge. This approach created significant constructability and access issues. Large excavations for the deep spread footings impacted U.S. 60, the BNSF Railway, and underground utilities. It also resulted in aesthetic inconsistencies among the bridge substructure elements.
PROFILE
ESTRELLA UNDERPASS AT GRAND AVENUE / SURPRISE, ARIZONA
BRIDGE DESIGN ENGINEER: Stanley Consultants, Phoenix, Ariz.
PRIME CONTRACTOR: Haydon Building Corp., Phoenix, Ariz.
PRECASTER: TPAC, Phoenix, Ariz.—a PCI-certified producer
POST-TENSIONING CONTRACTOR: Dywidag Systems International, Long Beach, Calif.
OTHER MATERIAL SUPPLIERS: Reinforcing Bar Producer: Nucor Steel LLC, Kingman, Ariz.; Reinforcing Bar Fabricator: CMC Rebar, Mesa, Ariz.; and Reinforcing Bar Installation: Endo Steel, Gilbert, Ariz.
AWARDS: 2016 CRSI Honors Award and 2016 American Council of Engineering Companies (ACEC) Grand Award